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Abstract
This paper presents calculated heat transfer coefficients for water vapor condensation on horizontal tubes.
The influence of vapor, cooling water and noncondensable gases properties on heat transfer process are presented. Two types of condensers are analyzed. One of them is a power plant condenser; the second is an
absorption refrigerator condenser where the working pair is water and Lithium Bromide (LiBr). Results for
tubes selected from different places in tube banks from both types of condensers are compared.
1. Introduction
Shell and tube heat exchangers are used as absorption refrigerator condensers as well as power plant
condensers. The Institute of Heat Engineering has
been conducting research into shell and tube power
plant condensers for many years now. One result
of these investigations is a numerical model and related computer program for these types of condenser.
The program simulates the behavior of steam vapor in a condenser using the Finite Elements Method
(FEM). Two types of condenser will be compared in
this paper: the well-known power plant condensers
[1] and the absorption refrigerator condenser. At issue is whether the numerical model that has been developed can be used to simulate the work of absorption refrigerator condensers.
The heat transfer rate for a single tube can be represented by Equation 1. Total thermal resistance R is
a sum of partial resistances which represent:
water side thermal resistance Rw ;
Corresponding author
Email addresses:
rrt (Andrzej
Grzebielec), rtrrst (Artur
Rusowicz)
(1)
where
do
Rw + Rd + R p + Ra + Rv
(2)
di
The heat transfer to water flowing inside a tube
is called internal forced convection. The correlation
[2] of heat transfer coefficient hw for turbulent flow
inside a tube is defined by Equation 3.
R=
kw 0.8 0.4
Re Pr
(3)
di
The fouling deposit formation has a significant impact on heat transfer in shell and tube condensers.
The investigation [3] determined that fouling deposit mean heat transfer coefficient hd in power
plant condensers is hd =25 kW/(m2 K). In individual
pipes this value was changed from 10 kW/(m2 K) to
35 kW/(m2 K). Sometimes, in condensers without automatic cleaning, after a long period of last manual
hw = 0.023
do ln
do
di
(4)
2 kp
h v
= N 1/6
(7)
hv (N = 1)
The heat transfer coefficient obtained from the
Nusselt correlation does not take steam velocity into
consideration. If in a shell and tube condenser steam
is flowing with a significant value, Equations 8, 9, 10
[7] will be used to calculate heat transfer coefficient
hv for the tube bundle.
hv =
h sh = 1.26
(5)
p
Da 1/2
Re
do
p ps
p1/3 s
r
tv
2/3
1
(tv tc )1/3
1
Xtt
0.78
(9)
hL
(N 1) + (N)
(N)
(10)
2. Description of condensers
where
hv = 0.725
(8)
where
hgrav = hv (N = 1)
ha =
h2sh + h2grav
0.25
(6)
During condensation on a tube bundle, the condensed water from the above tubes inundates the
tubes below. The mean heat transfer h v coefficient
of the first N rows can be expressed by Equation 7
[6], because the temperature difference between the
tube wall temperature and the saturated temperature
in both condenser types is under 14 K.
The power plant condenser selected here is a typical condenser operating at Belchatow, Poland. The
experimental data in terms of the pressure and temperature for this condenser are available [8], so the
predictions can be compared against the experimental data to validate the proposed numerical simulation [9, 10]. The grid used for the simulation are
presented in Fig. 1 [11]. The velocity vector plot and
contour map of steam pressure are shown in Fig. 1,
too.
The absorption refrigerator condenser is a typical
condenser used in one-stage absorption refrigerators
where the working pair is water and Lithium Bromide (LiBr). The condenser and generator have the
same working area. Cooling water at first cools the
absorber and then flows into the condenser. The geometric and operating parameters for both types of
condensers are given in Table 1.
Fig. 1a shows the grid used for simulation. The
grid shows the tube bundle border. Fig. 1b presents
steam velocity vectors. The vectors show the directions and values of steam velocity. It is possible to
obtain the steam velocity direction and value on every tube. Fig. 1c represents steam pressure changes
inside the condenser. In the area without tubes the
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6400
6400
6500
6500
6500
6500
6600
6300
6400
6500
6600
6700
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Parameter:
Tube outside diameter [mm]
Tube wall thickness [mm]
Tube length [mm]
Number of tubes
Number of passes
C.W. Inlet Temperature [o C]
C.W. Outlet Temperature [o C]
Cooling water flow [kg/h]
Steam inlet pressure [Pa]
Absorption refrigerator
condenser
25.4
0.7
6820
145
1
33.33
36.63
424490
7442
The faster flow of cooling water means lower thermal resistance, but in working condensers water velocity cannot be increased ad infinitum, because it
has other unwanted effects. When water flows faster,
corrosion and pressure drop will increase. When water from the sea or a lake is used in the condenser, the
velocity of cooling water should be between 1.2 and
2.4 m/s. The higher value is for cleaner water. On
the other side, when velocity is low, fouling deposit
formation will be faster. Optimizing water velocity
is of key importance for shell and tube condensers.
Fig. 3 illustrates the relationship between cooling
water inlet temperature and thermal resistance. In
both types of condenser, when the inlet temperature
of cooling water rises, both thermal resistances waterside Rw and steam side Rv will decrease. The thermal resistance on the steam side decreases due to the
lower temperature difference between the steam and
tube surface temperatures. Condensate film thickness is smaller. But this phenomenon has a very unwanted effect the heat transfer rate decreases to a
great extent. In working plants the engineer has to
choose between lower thermal resistance or a lower
heat transfer rate. In most known plants the inlet temperature of cooling water is 10 to 15 K lower than the
steam vaporization temperature.
Fig. 4 illustrates the relationship between vapor
velocity and thermal resistance. Vapor velocity has
a significant influence on the heat transfer process.
When velocity increases, steam side thermal resistance decreases. This phenomenon is a consequence
of smaller condensate film thickness. Inflowing
steam with faster velocity does not let film form a
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0.00035
0.00035
0.00030
0.00025
0.00020
0.00015
0.00010
m2 K
W
0.00040
0.00030
thermal resistance
0.00040
m2 K
W
0.00045
thermal resistance
0.00045
0.00025
0.00005
0.00020
0.00015
0.00010
0.00005
0.00000
0.00000
2.0
1.0
3.0
4.0
5.0
2.0
1.0
m
s
3.0
4.0
5.0
m
s
Figure 2: Relationship of cooling water velocity to thermal resistance. Absorption refrigerator condenser left side. Power plant
condenser right side
Rw
Rd
Rp
0.00035
0.00035
0.00030
0.00025
0.00020
0.00015
0.00010
m2 K
W
0.00040
0.00030
thermal resistance
0.00040
m2 K
W
0.00045
thermal resistance
0.00045
0.00025
0.00020
0.00015
0.00010
0.00005
0.00005
0.00000
0.00000
10
12
14
16
18
20
22
Rv
24
20
22
24
26
28
30
32
34
36
Figure 3: Relationship between cooling water inlet temperature and thermal resistance. Absorption refrigerator condenser left
side. Power plant condenser right side
Rw
Rd
45
Rp
Rv
m2 K
W
m2 K
W
0.00035
0.00030
thermal resistance
0.00035
0.00025
0.00025
0.00020
0.00020
0.00015
0.00015
0.00010
0.00010
0.00005
0.00005
0.00000
0.00030
0.00000
m
vapour velocity s
m
vapour velocity s
Figure 4: Relationship between vapor velocity and thermal resistance. Absorption refrigerator condenser left side. Power plant
condenser right side
Rw
Rd
Rp
Rv
46
0.00100
0.00090
0.00090
0.00080
0.00080
0.00070
0.00070
m2 K
W
0.00100
0.00060
thermal resistance
thermal resistance
m2 K
W
0.00050
0.00040
0.00030
0.00020
0.00010
0.00060
0.00050
0.00040
0.00030
0.00020
0.00010
0.00000
0.00000
0.00001
0.0001
0.001
0.00001
kgair
ncondensable gases mass fraction
kg
0.0001
0.001
kgair
ncondensable gases mass fraction
kg
Figure 5: Relationship between noncondensable gases mass fraction and thermal resistance. Absorption refrigerator condenser
left side. Power plant condenser right side
Rd
Rp
Ra
0.00100
0.00090
0.00090
0.00080
0.00080
0.00070
0.00070
m2 K
W
0.00100
0.00060
thermal resistance
thermal resistance
m2 K
W
Rw
0.00050
0.00040
0.00030
0.00020
0.00010
0.00060
0.00050
0.00040
0.00030
0.00020
0.00010
0.00000
0.00001
Rv
0.00000
0.0001
0.001
0.00001
m2 K
fouling thermal resistance
W
0.0001
0.001
m2 K
fouling thermal resistance
W
Figure 6: Relationship between fouling deposit thermal resistance and thermal resistance. Absorption refrigerator condenser left
side. Power plant condenser right side
Rw
Rd
47
Rp
Rv
Nomenclature
Aheat transfer area, m2
c p specific heat of condensate, J/kg/K
Qheat
transfer rate, W
rlatent heat of condensation, J/kg
r effective
latent
heat
of
condensation,
r 1 + 0.68 c p (t s tt ) /r
Rtotal thermal resistance, m2 K/W
Ra noncondensable gases thermal resistance, 1/ha
Rd fouling thermal resistance, 1/hd
R p wall resistance, m2 K/W
Rv condensate thermal resistance, 1/hv
Rw water side thermal resistance, 1/hw
ReRe Reynolds number, s v s do / s
Res two phase Reynolds number, c v s do /c
xvapor quality - vapor mass flow rate/total -mass
flow rate
Xtt Lockhart-Martinelli parameter, ((1 x) /x)0.9
( s /c )0.5 (c / s )0.1
empirical exponent, 0.13 for triangular tube layouts, 0.22 for square tube layouts
condensation rate from one tube onto tube below,
(N do hv (t s tt )) /r
c condensate density, kg/m3
s steam density, kg/m3
s dynamic viscosity of steam, N s/m2
s kinematic viscosity of steam, m2 /s
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